HYDRAULIC WINCH80RVSHY / 80RVSDY / 10RVSHY / 15RVSHY / 18RVSHY
Assembly & Operating Instructions
INTRODUCTION
We have developed several new series that make up the current product line. Each series in our product line has unique design characteristics; many new patented technologies are integrated into our winches. Your HWP series winch is part of our new product line and has its own salient features: two speeds, single shaft clutch and speed control, and automatic reducer gear engagement. There are three positions of reducer gear engagement, high gear, low gear, and free spool. This new technology has made winches the pinnacle in user convenience and reliability. You will take pride in knowing that your new winch has been designed to work as hard as you and that it will be there when you need it.Congratulations on your purchase of a highest-class advanced powerful two-speed winch. We design and build winches to strict specifications and with proper use and maintenance should bring you years of satisfying service.
WARNING – Read, study and follow all instructions before operating this device. Failure to heed these instructions may result in personal injury and/or property damage.Your winch can develop tremendous pulling forces and if used unsafely or improperly could result in property damage, serious injury or death. Throughout this manual you will find the following symbols for caution, warning and danger. Pay particular attention to the notes preceded by these symbols as they are written for your safety. Ultimately, safe operation of this device rests with you, the operator.
SAFETY WARNINGS AND PRECAUTIONS
WINCH WARNINGS AND PRECAUTIONS
UNPACKING
When unpacking, check to make sure all parts are included. Refer to Assembly Drawings and Parts List (both with the like item numbers) at the end of this manual.
INSTALLATION
1. Your winch is designed with a bolt pattern that is standard in this class of winch. Many winch mounting kits are available that utilize this bolt pattern for the most popular vehicle and mounting channels. If you cannot find a kit locally, contact us and we will provide you with the name of a dealer near you. If you will utilize the mounting channel you must ensure that it is mounted on a flat surface so that the three major sections (motor, drum and gear housing) are properly aligned. Proper alignment of the winch will allow even distribution of the full rated load.2. Mount winch to the vehicle using high strength cap screw. It should be aligned and secured to a solid part of the vehicle (front or rear) where the full rated load will be evenly distributed.3. Please refer to the installation illustration.
Working hydraulic principle chart and installation illustration:
Below is an installation illustration of winch:
Below is an installation illustration with roller fairlead of winch:
OPERATION
General information:
Winch’s standard equipment contain gear reducer、drum、hydraulic motor, solenoid valve、switch assembly、female connector and plumbing fittings. The winch obtains its pressure from the vehicle’s existing power steering pump or other hydraulic power. The winch is totally sealed, can be used underwater. There are several other ways to supply power to the winch. The first way is to use an individual pump for engineering use. The second way is to provide the winch’s hydraulic pressure is with the vehicle’s exiting power steering pump (See Installation Instructions).① Use a suitable individual pump, which doesn’t have an oil pressure relief valve. It will supply pressure for both the steering box and the winch.② Use a combined pump with an integrated oil valve. The oil valve will supply two kinds of flow based on the difference in demand. One type of flow will be constant and should be used with the steering system. The other will provide higher pressure and is for engineering use.
Winch working demonstration:
1. Disengage the clutch by turning the clutch to the “CLUTCH OUT” position.2. Grab the cable assembly and pull the cable to the desired length, then attach to item being pulled.Caution: Always leave at least five turns of cable on the drum; Review Winch Safety Warnings and Precautions on page 2、3 before continuing.3. Reengage the clutch by turning the clutch assembly to the “CLUTCH IN” position as needed.4. Test-run winch in both directions. Turn the winch in each direction for about one or two seconds meantime make the clutch totally engaged automatically.5. While standing aside of the tow path, hold and operate the switch assembly supplied by your choice. Wait until the motor stops before reversing directions.
WINCH ACCESSORIES YOU WILL NEED
NOT INCLUDED WITH YOUR WINCHGloves – For handling the wire rope and hook strap.Anchor Strap/Chain – Tree saver anchor straps are made of high-quality nylon with high tensile strengths up to 15000lbs.Heavy Blanket – place on the cable to absorb energy should the wire rope break.
RIGGING TECHNIQUES
Self-Recovery
Locate a suitable anchor such as a strong tree trunk or boulder. Always use a sling as an anchor point.
When pulling a heavy load, place a blanket or jacket over the wire rope five or six feet from the hook. In the event of a broken cable it will dampen the snapback. For additional protection open the hood of the vehicle as shown in Fig 3.3
For pulls over 70% rated line pull, we recommend the use of the snatch block/pulley block to double line the wire rope. Fig 3.4 This reduces the load on the winch and the strain on the rope by up to 50% depending on the included angle.
WARNING – Never use your winch for overhead hoisting or for lifting people or moving people.
LUBRICATION
1. All moving parts within the Winch having been Lubricated using high-temperature lithium grease at the factory. No internal lubrication is required.2. Lubricate Cable Assembly periodically using a light penetrating oil.
CABLE ASSEMBLY REPLACEMENT
If the wire rope has become worn or is beginning to show signs of strands breaking, it must be replaced before being used again.1. Turning clutch to the “CLUTCH OUT” position.2. Extend cable assembly to its full length. Note how the existing cable is connected to the drum.3. Remove old cable assembly and attach new one as the ld cable connected to the drum. Insert the end of the new rope and secure the screw being tightly screwed4. Turning clutch to the “CLUTCH IN” position.5. Retract cable assembly onto drum, first five wraps being careful not to allow kinking, then winch cable must be wound onto the drum under a load of at least 10% rated line pull.
TROUBLESHOOTING
SYMPTOM | POSSIBLE CAUSE | SUGGESTED ACTION |
Winch does not turn . | -Insufficiently hydraulic system pressure.-Improper connections of hydraulic system, no oil into motor. | -Check relief valve regulate pressure.-Check all the plumbing fixtures according to the working principle chart.-Defective directional control valve. |
Motor runs but Cable drum does not turn | – The clutch is Notengaged | -Turn the clutch to the high or lows peed position. If problem still persists, a qualified technician needed to check and repair. |
Winch drum runs slowly or without normal power. | -Insufficient pressure or oil flow-Insufficient fluid in the system– Wrong winch working and nd motor. | -Bump is not suitable or defective. Change a new one or a suitable one-Check fluid level. Add fluid until full. -Change the connection of balance valve |
Winch cannot spool off wire rope with load smoothly. | -Wrong winch working direction. | -Change the connection of balance valve and motor. |
WINCH ASSEMBLY DRAWING
(80RVSHY/80RVSDY/10RVSHY)
WINCH PARTS LIST
(80RVSHY/80RVSDY/10RVSHY)
No. | Part # | OlY | Desaiplion | Remark |
1 | HV1000001 | 1 | Figh-ccessure oil tube | |
2 | HV1000002 | 2 | Oil connection | |
3 | HV1000003 | 2 | Combination Washer 14 | |
4 | HV1000004 | 2 | Cap Screw M12 x 30 | |
5 | HV1000005 | 2 | Lock Washer 012 | |
6 | HV1000100-1 | 1 | Hydraulic Motor | used MCORVSHYOORVSDY |
HV1000100-2 | 1 | Hydraulic Motor | Used in 10FIVSHY | |
7 | HV10000013 | 1 | Blanced valve | |
8 | HV1000007 | 4 | Cap Screw PA8 x 55 | |
9 | HV1000008 | 12 | Lock Washer 08 | |
10 | HV1000009 | 8 | Screw M8 x 30 | |
11 | HV1000010 | 1 | Brake slants | |
12 | HV1000011 | 3 | Brake block | |
13 | HV1000012 | 2 | Friction plate | |
14 | HV1000013 | 2 | 0-ring seal 100’3.55 | |
15 | HV1000014 | 1 | Piston | |
18 | HV1000015 | 1 | 0-ring seal 140’2.85 | |
17 | HV1000016 | 2 | Disk wring | |
18 | HV1000017 | 2 | O-ring seal 118’3.55 | |
19 | HV1000018 | 1 | Motor bracket | |
20 | HV1000019 | 1 | Coupling | |
21 | HV1000020-1 | 1 | Transmission shaft | 1.;:ec n 07RWMY IORVSHY |
HV1000020-2 | 1 | Transmission shaft | Used S. 8ORVSDY | |
22 | HV1000021 | 2 | Bearing bush | |
23 | HV1000022 | 2 | Rig Seals | |
24 | HV1000023 | 8 | ScrewM10 x 25 | |
25 | HV1000024 | 16 | Lock Washer 010 | |
213 | HV1000025-1 | 1 | Stand bar ( b ) | usedinconvsmy IORVSHY |
HV1000025-2 | 1 | Stand bar ( b ) | Used in 80FIVSDY | |
27 | HV10000213-1 | 1 | Staal bar ( a ) | Used In OORVSHY IORVffire |
HV1000026-2 | 1 | Staal bar ( a ) | Used in 80FIVSDY | |
28 | HV1000027 | 2 | Screw M8 x 15 | |
29 | HV1000200-1 | 1 | Dorn Assembly | Use* in CIORVSHY IORVI3HY |
HV1000200-2 | 1 | Drum Assembly | Used in801111SW | |
30 | HV1000028 | I | C0-0119 I | |
31 | HV1000029 | 16 | Cap Screw MO x 20 | |
32 | HV11:100030 | 16 | Lock Washer 443 | |
33 | HV1000031 | 1 | End Beari-ig | |
34 | HV1000300 | 1 | Gear Carrier Assembly (Output, | |
35 | HV1000032 | 2 | Gasket | |
38 | HV1000033 | 1 | Gear-Rng Φ Outputs | |
37 | HV1000400 | 1 | Gear Carrier Assembly I haul/ | |
38 | HV1000034 | 1 | Clain for hole 0125 | |
39 | HV1000035 | 1 | Gear-Rig I Input/ | |
40 | HV1000038 | 1 | Gear—Input Sun | |
41 | HV1000037 | 1 | Trust Washer | |
42 | HV1000038 | 1 | Me sleeve | |
43 | HV1000039 | 1 | Cover-Gear Housiog | |
44 | HV1000500 | 1 | Clutch Assembly | |
45 | HV1000040 | 8 | Screw M10 x 35 | |
46 | HV1000041 | 8 | Think Flat Washer 010 | |
47 | HV1000600-1 | 1 | Roller Fairlead | Used in 8ORVSHY lORVSHY |
HV1000600-2 | 1 | Roller Fairlead | Used in 8ORVSDY | |
48 | HV1000700-1 | 1 | Cable Assembly | Used in 8ORVSHY 8ORVSDY |
HV1000700-2 | 1 | Cable Assembly | Used in 1ORVSHY | |
49 | HV1000800-1 | 1 | Tensioned Of Steel Wire Supplied Assembly | Used in 8ORVSHY lORVSHY |
HV1000800-2 | 1 | Tensioned Of Steel Wire Supplied Assembly | Used in 8ORVSDY |
OUTLINE DIMENSIONAL DRAWING
WINCH ASSEMBLY DRAWING (15RVSHY/18RVSHY)
WINCH PARTS LIST (15RVSHY/18RVSHY)
No. | Part # | Qty | Description | Remark |
1 | HV1500001 | 1 | High-pressure oil tube | |
2 | HV1500002 | 2 | Oil connection Oil | |
3 | HV1500003 | 2 | Combination Washer 14 | |
4 | HV1500004 | 2 | Cap Screw M12 x 30 | |
5 | HV1500005 | 2 | Lock Washer Φ12 | |
6 | HV1500100-1 | 1 | Hydraulic Motor | Used in 15RVSHY |
HV1500100-2 | 1 | Hydraulic Motor | Used in 18RVSHY | |
7 | HV1500006 | 1 | Balanced valve | |
8 | HV1500007 | 4 | Cap Screw M8 x 55 | |
9 | HV1500008 | 36 | Lock Washer Φ8 | |
10 | HV1500009 | 8 | Screw M8 x 30 | |
11 | HV1500010 | 1 | Brake stents | |
12 | HV1500011 | 3 | Brake block | |
13 | HV1500012 | 2 | Friction plate | |
14 | HV1500013 | 2 | 0-ring seal 100’3.55 | |
15 | HV1500014 | 1 | Piston | |
16 | HV1500015 | 1 | 0-ring seal 140’2.65 | |
17 | HV1500016 | 2 | Disk spring | |
18 | HV1500017 | 2 | 0-ring seal 118’3.55 | |
19 | HV1500018 | 1 | Motor mounting plate | |
20 | HV1500019 | 3 | Gasket | |
21 | HV 1500020 | 1 | Motor bracket | |
22 | HV1500021 | 24 | Screw M8 x 25 | |
23 | HV1500022 | 1 | Coupling | |
24 | HV1500023 | 1 | Transmission shaft | |
25 | HV1500024 | 2 | Bearing bush | |
26 | HV1500025 | 2 | Ring Seals | |
27 | HV1500026 | 8 | Screw M10 x 25 | |
28 | HV1500027 | 16 | Lock Washer Φ10 | |
29 | HV1500028 | 1 | Stand bar(a) | |
30 | HV1500029 | 1 | Stand bar(b) | |
31 | HV1500030 | 2 | Screw M8 x 15 | |
32 | HV1500200-1 | 1 | Drum Assembly | Used in 15RVSHY |
HV1500200-2 | 1 | Drum Assembly | Used in 18RVSHY | |
33 | HV1500031 | 1 | Coupling I | |
34 | HV1500032 | 1 | End Bearing | |
35 | HV1500300 | 1 | Gear Carrier Assembly (Output) | |
36 | HV1500033 | 1 | Gear-Ring (Output) | |
37 | HV1500400 | 1 | Gear Carrier Assembly (Input) | |
38 | HV1500034 | 1 | Credit for hole Φ125 | |
39 | HV1500035 | 1 | Gear-Ring ( Input ) | |
40 | HV1500036 | 1 | Gear—Input Sun | |
41 | HV1500037 | 1 | Trust Washer | |
42 | HV1500038 | 1 | Axle sleeve | |
43 | HV 1500039 | 1 | Cover-Gear Housing | |
44 | HV1500500 | 1 | Clutch Assembly | |
45 | HV1500040 | 8 | Screw M10 x 35 | |
46 | HV1500041 | 8 | Think Flat Washer Φ10 |
47 | HV1500600 | 1 | Roller Fairlead | |
48 | HV1500700-1 | 1 | Cable Assembly | Used in 15RVSHY |
HV1500700-2 | 1 | Cable Assembly | Used in 18RVSHY | |
49 | HV1500800 | 1 | Tensioned Of Steel Wire Supplied Assembly |
OUTLINE DIMENSIONAL DRAWING
SPECIFICATION(80RVSHY)
Rated line pull | 8000 lbs (3629 kgs) |
Motor displacement | 80m1/r |
Oil flow | 5-60L/min |
Pressure | 12Mpa |
Gear reduction ratio | 17.6:1 |
Cable (Dia. x L) | Ø3/8″x 98.4′ (Ø9.2mm x 30.0m) |
Drum size(Dia. x L) | Ø4.0 “x 7.91” (Ø102mm x 201 mm) |
Mounting boltpattern | 10″x 4.5 ” (254mm x 114.3mm) ;10″x 6.5″ (254mm x 165.1mm) 8-M10 |
Overall dimensions(LxWxH) | 23.23″ x 9.3″ x 9.5″590mm x 237mm x 241 mm |
Net weightlbs(kg) | 10849 |
Pull, Speed, Pressure, Flow (First layer)
Line pull lbs (kgs) | Pressure Mpa(Psi) | Flow G/min (L/min) | Line speed ft/min(m/min) |
0 | 2.0(290.1) | 1.3(5) | 3.2(1.0) |
4000(1814) | 5.0(725.2) | 5.3(20) | 10.8(3.3) |
6000(2722) | 8.0(1160.3) | 10.5(40) | 23.9(7.3) |
8000(3629) | 12.0(1740.4) | 15.8(60) | 37.7(11.5) |
Line Pull And Rope Capacity Inlayer
Layer of wire rope | Rated line pull lbs(kgs) | Total rope on drum ft (m) |
1 | 8000(3629) | 21.3(6.5) |
2 | 6864(3113) | 49.2(15.0) |
3 | 6010(2726) | 80.4(24.5) |
4 | 5345(2424) | 98.4(30.0) |
SPECIFICATION(80RVSDY)
Rated line pull | 8000 lbs (3629 kgs) |
Motor displacement | 80m1/r |
Oil flow | 5 -60L/min |
Pressure | 12Mpa |
Gear reduction ratio | 17.6:1 |
Cable (Dia. x L) | Ø3/8″ x 98.4′ (Ø9.2mm x 30.0m) |
Drum size(Dia. x L) | Ø4.0 ” x 6.65″ (Ø102mm x 169mm) |
Mounting boltpattern | 8.74″ x 4.5 ” (222mm x 114.3mm) :8.74″ x 6.5″ (222mm x 165.1mm) 8-M10 |
Overall dimensions(LxWx H) | 22.0″ x 9.3″ x 9.5″558mm x 237mm x 241mm |
Net weightlbs(kg) | 10547.6 |
Pull , Speed, Pressure, Flow (First layer)
Line pull lbs (kgs) | Pressure Mpa(Psi) | Flow G/min (L/min) | Line speed ftlmin(m/min) |
0 | 2.0(290.1) | 1.3(5) | 3.2(1.0) |
4000(1814) | 5.0(725.2) | 5.3(20) | 10.8(3.3) |
6000(2722) | 8.0(1160.3) | 10.5(40) | 23.9(7.3) |
8000(3629) | 12.0(1740.4) | 15.8(60) | 37.7(11.5) |
Line Pull And Rope Capacity Inlayer
Layer of wire rope | Rated line pull lbs(kgs) | Total rope on drum ft (m) |
1 | 8000(3629) | 18.4(5.6) |
2 | 6864(3113) | 42.3(12.9) |
3 | 6010(2726) | 69.5(21.2) |
4 | 5345(2424) | 98.4(30.0) |
SPECIFICATION(10RVSHY)
Rated line pull | 10000 lbs (4536 kgs) |
Motor displacement | 100mUr |
Oil flow | 5-60L/min |
Pressure | 15Mpa |
Gear reduction ratio | 17.6:1 |
Cable (Dia. X L) | Ø13/32-X98.4′ (Ø10.2mm X 30.0m) |
Drum sin(D18.X L) | Ø4.0′ X 7.91″ Ø102mm X 201mm) |
Mounting boltpattern | 10″X 4.5 – (254mm X 114.3mm)10″ X6.5′ (254mm X 165.1 mm) 8-M10 |
Overall dimensions(LXWXH) | 23.4’X9.3″X9.5a594mm X 237mm X 241mm |
Net weightlbs(kg) | 11049.9 |
Pull, Speed, Pressure, Flow (First layer)
Line pull lbs (kgs) | Pressure Mpa(PsI) | Flow G/min (Urnin) | Line speedfUmin(rn/min) |
0 | 3.0(435.1) | 1.3(5) | 3.0(0.9) |
4000(1814) | 6.8(986.2) | 2.6(10) | 5.9(1.8) |
6000(2722) | 9.2(1334.3) | 5.2(20) | 11.8 (3.6) |
8000(3629) | 12.0(1740.4) | 10.4(40) | 23.6(7.2) |
10000(4536) | 15.0(2175) | 15.6(60) | 36.1(11) |
Line Pull And Rope Capacity Inlayer
Layer of wire rope | Rated line pull lbs(kgs) | Total rope on drum ft (m) |
1 | 10000(4536) | 23.0(7.0) |
2 | 7355(3336) | 49.2(15.0) |
3 | 6780(3075) | 78.7(24.0) |
4 | 5711(2591) | 98.4(30.0) |
SPECIFICATION(15RVSHY)
Rated line pull | 15000 lbs (6804 kgs) |
Motor displacement | 160m1/r |
Oil flow | 5 – 60Umin |
Pressure | 17.5Mpa |
Gear reduction ratio | 17.3:1 |
Cable (Dia. X L) | Ø15/32″ x 98.4′ (Ø12mm X 30.0m) |
Drum size(Dia. X L) | Ø5.0 “x 10.5′ (Ø127mm X 266mm) |
Mounting boltpattern | 12.0 “X 4.5 – (303.5mm X 114.3mm) :14.5 ” X 6.7″ (368.5mm X 171.2mm) 8-M12 |
Overall dimensions(LxWXH) | 28.9″ X 11.8″ X 10.9″735mm X 300mm X 277mm |
Net weightlbs(kg) | 184.383.6 |
Pull , Speed, Pressure, Flow (First layer)
Line pull lbs (kgs) | Pressure Mpa(Psi) | Flow G/min (Umin) | Line speedft/min(m/min) |
0 | 2.0(290) | 2.6(10) | 4.2(1.3) |
8000(3629) | 9.2(1337) | 5.2(20) | 8.5(2.6) |
10000(4536) | 11.5(1627) | 7.9(30) | 12.4 (3.8) |
12000(5448) | 14.0(2030) | 10.4(40) | 16.7(5.1) |
15000(6810) | 17.5(2537) | 15.6(60) | 23(7) |
Line Pull And Rope Capacity Inlayer
Layer of wire rope | Rated line pull lbs(kgs) | Total rope on drum ft (m) |
1 | 15000(6804) | 29.5(9.0) |
2 | 12791(5807) | 65.6(20.0) |
3 | 11150(5062) | 98.4(30.0) |
SPECIFICATION(18RVSHY)
Rated line pull | 18000 lbs (8165 kgs) |
Motor displacement | 200mVr |
Oil flow | 5 – 60Umin |
Pressure | 16Mpa |
Gear reduction ratio | 17.3:1 |
Cable (Dia. X L) | Ø9/16″ X 91.8′ (Ø14mm X 28.0m) |
Drum size(Dia. X L) | Ø5.0 “X 10.5” (Ø127mm X 266mm) |
Mounting boltpattern | 12.0 “X 4.5- (303.5mm X 114.3mm) :14.5 ” X 6.7″ (368.5mm X 171.2mm) 8-M12 |
Overall dimensions(LXWXH) | 29.2″ X11.8″ X 10.9″742mm x 300mm X 277mm |
Net weightlbs(kg) | 19086.2 |
Pull , Speed, Pressure, Flow (First layer)
Line pull lbs (kgs) | Pressure Mpa(Psi) | Flow G/min (Umin) | Line speedft/min(m/min) |
0 | 2.0(290.1) | 2.6(10) | 4.6(1.4) |
8000(3629) | 5.8(841.2) | 5.2(20) | 6.6(2.0) |
12000(5448) | 9.2(1334.3) | 10.4(40) | 13.1(4.0) |
15000(6810) | 12.0(1740.5) | 13.2(50) | 17.4(5.3) |
18000(8165) | 16.0(2320.6) | 15.6(60) | 24(7.3) |
Line Pull And Rope Capacity Inlayer
Layer of wire rope | Rated line pull lbs(kgs) | Total rope on drum ft (m) |
1 | 18000(8165) | 25.9(7.9) |
2 | 15017(6811) | 58.7(17.9) |
3 | 12882(5843) | 91.8(28.0) |
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